Board overlays and methods for same

Abstract

A board overlay including a surface layer having a first edge portion and a second edge portion, the first edge portion and the second edge portion extending along a length of the surface layer. The surface layer includes an exterior face positioned between the first edge portion and the second edge portion and one or more flashing drapes positioned on at least one of the first edge portion and the second edge portion.

Description

[0001] BOARD OVERLAYS AND METHODS FOR SAME

[0002] CLAIM FOR PRIORITY

[0003] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 659,934, filed June 14, 2024, which is hereby incorporated by reference in its entirety.

[0004] TECHNICAL FIELD

[0005] This document pertains generally, but not byway of limitation, to overlays, wraps, coverings or the like applied to structural members, such as boards, planks, panels or the like.

[0006] BACKGROUND

[0007] Outdoor structures, such as patios, decks, furnishing, flooring, or the like are, in various examples, formed with lumber, composites or polymer-based materials. For example, decks, patios, walkways, railings, fences, or the like are constructed from boards, planks, panels, beams, or the like (hereinafter “board” or “boards”). Lumber or polymer-based materials are selected based on user specified aesthetics, wear characteristics, or the like. In some examples, the boards are used in outdoor conditions or environments that advance decay, decomposition, or other damage to the lumber. For example, lumber-based products decay, warp, lose luster or finish due to outdoor conditions such as weather, solar exposure, and use.

[0008] OVERVIEW

[0009] The present inventors have recognized, among other things, that a problem to be solved includes protecting boards, such as outdoor boards formed from lumber, composites, polymers, or the like from environmental conditions.

[0010] Optionally, the board is refinished by stripping the old finish and applying a new finish (e.g., paint, sealant, stain, or the like) to restore the appearance and extend the life of the board. In such examples, the finish is painted, sprayed or the like onto the existing boards. In some examples, refmishing is cost-effective relative to replacing the board. Refmishing at times is subject to wear over time and corresponding re-application. In other examples, refinishing a board includes refinishing with liquid sealants that shield the board from ultraviolet (UV) rays that cause fading and deterioration. In other examples, liquid sealants and finishes enhance resistance to scratches, dents, and other forms of physical damage to the board. The sealants are ablative, and accordingly re-application is conducted to restore the benefits of the sealant.

[0011] Boards such as components of decks, patios, walkways, railings, fences, furnishings or the like are constructed from boards, planks, panels, beams are optionally formed of a material including one or more of lumber, composite, polymer, or the like are subject to deformation, decay, warping or the like. In some examples, weather, sun exposure, combinations of the same or the like break down the board and initiate decay, deformation, or warping. Usually, regular maintenance for boards is recommended to reduce damage and elongate the lifespan of a board. In some examples, even with regular maintenance, including staining, finishing, sealing, or the like replacement of the board is warranted.

[0012] In some situations, refinishing a board includes reconditioning the surface of the boards, such as applying paints, stains, or other coatings. In some examples, a protective (optionally aesthetic) liquid finish is applied to protect the board by painting, spraying or the like. Over time, such finishes wear and break down and require stripping and refmishing. Further, the application of liquid finish is, in some examples, inconsistent. For instance, one or more supplemental applications are missed, or portions of the board are not fully covered with the finish. The missed or partially covered portions of the board sometimes have a visible variation in decorative appearance or are subject to uneven wear, and accordingly decay, deformation or warping are aggravated relative to fully finished portions of the board. Optionally, instead of applying a liquid coating, the board is at least partially replaced if the appearance or condition is not appealing to the user.

[0013] In other examples, the present inventors have recognized, among other things, that a problem to be solved includes changing the appearance of a board (such as components of decks, patios, walkways, railings, fences, furnishings or the like are constructed from boards, planks, panels, beams). For example, changing the appearance of an outdoor board includes application of a different finish (e.g., stain, varnish, paint, or the like) or installing a new outdoor board. In examples, paint discolors, cracks, chips, or the like (collectively, degrades) and the outdoor board is repainted or replaced. In some examples, replacing or installing a new outdoor board is expensive, labor intensive or both.

[0014] The present inventors have found solutions to one or both of protecting or changing the appearance of outdoor boards without using finishes that degrade and require re-application, such as stains, varnishes, paints, sealants, or the like. The present inventors have developed an overlay, such as a board overlay, installed along a board. The board overlay protects the board and optionally changes the appearance of the board. The board overlay is coupled (e.g., adhered, fastened, joined, or the like) to a board. For example, the board overlay covers boards (e.g., components of decks, patios, walkways, railings, fences, furnishings or the like are constructed from boards, planks, panels, beams or the like) of a porch, deck, floor, walkway, siding, post, or the like.

[0015] The board overlay is, for example, formed from pliable components including a surface layer and a coupling layer. In examples, the surface layer and the coupling layer are formed from pliable materials that complement the contour of the board, such as forming a complementary surface to surface fit against the board. For example, the board overlay is coupled along the surfaces of the board. In an example, the board overlay is applied to at least three sides of the board. In another example, the board overlay is formed from a less pliable (e.g., molded or extruded-type shell) material. Optionally, the board is formed from High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE) or polypropylene. The material selected for the board overlay is, in one example, specified by purpose. In some examples, a board overlay having increased pliability relative to a less pliable overlay is used to achieve a specified complementary fit of the overlay to the board. In some examples, the pliable board overlay is stiffened after application.

[0016] In an example, the board overlay includes, for example a surface layer and a coupling layer. The surface layer, for example, includes a polymer material. In an example, the surface layer is a strip, ribbon, slab, sheet, or the like. For example, the surface layer includes an exterior face and a surface layer interface. In some examples, the surface layer interface is an inner, or under, surface opposed to the exterior face. In other examples, the surface layer interface facilitates coupling with the board, such as adhering, fastening or the like in a complementary manner to the board. In still other examples, the surface layer interface facilitates coupling with the coupling layer, described herein. As described herein, the surface layer of the board overlay is an outer layer of the board overlay. The surface layer includes an exterior face directed toward the exterior (e.g., away from the board). In some examples, the exterior face includes a textured or partially textured surface. In other examples, a laminated layer is applied to the exterior face of the surface layer. For instance, the laminated layer includes, but is not limited to, an image, color, pattern, or profile that is applied to the surface layer and provides the image, color, pattern, or profile along the exterior face. In other examples, the laminated layer, includes a textured contour (e.g., as a component layer) such as a tractional surface. In further examples, the exterior face includes the appearance of a textured or partially textured surface, such as painting, pictures or the like that provide an aesthetic or decorative appearance as well as a profile including a texture. Optionally, the surface layer is printed with a pattern, texture, solid print, or the like during manufacturing.

[0017] The surface layer optionally includes a coating, such as a polymer or an acrylic. In some examples, the coating enhances one or more of durability, toughness, or the like of the surface layer. In examples, the coating is painted, sprayed, or otherwise applied on the surface layer. For example, the coating is applied during the manufacturing process as the surface layer is formed (e.g., extruded, or coextruded) or subsequent to the surface layer production (e.g., after setting of the surface layer). For instance, the surface layer is co-extruded with the coating having enhanced properties. In another example, the surface layer includes a streaked wood grain appearance. In such an example, the material optionally passes through a secondary mechanism during manufacturing that applies (e.g., inject, insert, paint, print or the like) one or more of color, streaks, or contour to form a wood grain image or specified image.

[0018] The surface layer is, for example, pliable, or semi-pliable, and covers the board. For instance, when coupled to the board the surface layer protects the board from environmental elements (e.g., outdoor conditions) that cause wear or degradation (e.g., moisture, particulates, changes in temperature, sunlight, abrasion from use or the like).

[0019] In one example, the board overlay includes one or more flashing drapes positioned along one or more edge portions of the surface layer. In an example the one or more flashing drapes include a pliable flashing drape that wraps (e.g., pliably, flexibly or the like) over one or more of the first edge portion or the second edge portion. The flashing drapes extend from the one or more edge portions of the surface layer. For instance, the flashing drapes extend at an angle away from the exterior face. In a coupled configuration with a board, the flashing drapes extend at oblique directions from the one or more edge portions, for instance relative to the exterior face of the surface layer. For example, the flashing drapes are formed to extend beyond the outer edges of the board and pliably deform over the outer edges and fit along the first and second edge portions of the member in a complementary manner.

[0020] This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the invention. The detailed description is included to provide further information about the present patent application.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0023] Figure 1 is a cross section of an example of a schematic of a board.

[0024] Figure 2 is a cross section of an example of a schematic of a board including an overlay assembly coupled with a board.

[0025] Figure 3 is a cross section of another example of a board overlay assembly coupled with a board.

[0026] Figure 4 is a perspective view of an example of a board coupled with a board overlay assembly.

[0027] Figure 5A is a schematic of an example of a cross section of a board overlay assembly.

[0028] Figure 5B is a schematic of another example of a cross section of a board overlay assembly.

[0029] Figure 6A is a schematic of an example of a cross section of a board overlay assembly including an adhesive. Figure 6B is a schematic of another example of a cross section of a board overlay assembly including an adhesive.

[0030] Figure 6C is a schematic of another example of a cross section of a board overlay assembly including an adhesive.

[0031] Figure 7 is a schematic of an example of a cross section of a board and a board overlay assembly including a mechanical coupling.

[0032] Figure 8 is perspective view and detailed perspective view of a board overlay assembly and a mechanical coupling.

[0033] Figure 9 is a schematic of an example of a cross section of at least two boards and a board overlay assembly.

[0034] Figure 10 is a schematic of an example of a cross section of a board overlay assembly in a flat configuration.

[0035] Figure 11 is a schematic of one example of a method of forming a board overlay assembly.

[0036] DETAILED DESCRIPTION

[0037] The present inventors have developed an overlay, such as a board overlay, installed along a board. The board includes, for example, one or more of a lumber, composite, polymer, cement, or the like. When discussing a board herein the board includes, but is not limited to, such as components of decks, patios, walkways, railings, fences, furnishings or the like are constructed from boards, planks, panels, beams, or other structural members.

[0038] The board overlay in some examples protects the board. Optionally, the board overlay changes the appearance of the board. The board overlay is coupled (e.g., adhered, fastened, joined, or the like) to a board. When the board overlay is applied to the board, the board overlay, for instance, decreases the likelihood that moisture infiltrates spaces within the board and pooling of moisture on the board. Additionally, the board overlay including the flashing drapes described herein decreases accumulation of moisture between the overlay and the board.

[0039] In some examples, the board overlay is a comprehensive water management system. The water management system is, for example, designed to protect the underlying board from moisture infiltration and water damage. The system optionally includes multiple coordinated and cooperating features including, but not limited to, one or more of a strategically contoured exterior face, optimized flashing drape geometry, or controlled water channeling mechanisms to direct moisture away from vulnerable areas.

[0040] In some examples, an exterior face of a surface layer of a board overlay assembly that is applied to an underlying board includes a slight convex profile, with the center portion elevated relative to the edge portions of the board overlay assembly (e.g., plus 2 mm, plus 1 mm, plus 0.5 mm relative to the edges; 5 degrees, 7.5 degrees, or the like). For instance, this convex contour forms a slope that directs water toward the lateral edges of the member where flashing drapes are positioned. The flashing drapes include portions of the board overlay assembly and are configured to drape (e.g., hang over, wrap, or the like) along one or more side portions of the board. The curvature of the exterior face is calculated, for example, to balance aesthetic appearance with sufficient moisture shedding properties. In some examples, the radius of curvature provides slope for moisture movement while maintaining a substantially flat appearance or feel (e.g., haptic experience) to users.

[0041] The water management system of the board overlay assembly optionally functions effectively across various installation angles, including horizontal, angled, and vertical board installations. The flashing drapes maintain their water-shedding functionality whether the board is installed as decking, fascia, railing, or other architectural elements, providing protection regardless of orientation.

[0042] A transition zone between, for instance, the exterior face and the flashing drapes forms a continuous path that reduces water pooling at junctions between the flashing drapes and the remainder of the overlay (e.g., its central portion). In some examples, this transition zone includes channels or texture patterns that enhance moisture being directed away from the exterior surface of the board overlay assembly.

[0043] Illustrated in Figure 1 is a schematic cross section of a board 100. The board 100 include components of decks, patios, walkways, railings, fences, furnishings or the like, that are constructed from boards, planks, panels, beams, or other structural members. The board 100 includes structures onto which a board overlay (as will be describe later in detail) is applied. In an example, the board 100 is a structural board, such as, but not limited to, decking, lumber planks, polymer slats, composite boards, or the like. For example, the board 100 is a structural component that is included on a porch, deck, patio, or the like. The board 100 is optionally used to form railings, posts, seats (e.g., benches), tables, or the like.

[0044] The board 100 is optionally formed from lumber, or a composite that is used in structural or foundational components. In other examples, the board 100 is formed from wood, composites, polymers, cement, concrete, or the like. The board 100 is optionally, rectangular, square, or other geometric shape that is specified by the purpose. For instance, the board 100 includes a top surface 111 and an opposing bottom surface 113. While a stated as a top surface and a bottom surface, the orientation is a back and front surface. The board 100 includes two or more side surfaces 115. Each two or more side surfaces 115, for example connects the top surface 111 and the opposing bottom surface 113. One or more corner portions 117 are located, for example, at the junction of the top surface 111 with at least one of the two or more side surfaces 115 and at the aspect opposing bottom surface 113.

[0045] The surface of the board (including the top surface 111, opposing bottom surface 113, and two or more side surfaces 115) extend along the length of the board 100. The top surface 111 and the opposing bottom surface 113, in examples extend along a width of the board from one of the two or more side surfaces 115 to the other of the two or more side surfaces 115.

[0046] Figure 2 illustrates a schematic of a cross-section of a board overlay assembly 200. The board overlay assembly 200 includes, for example, a surface layer 210, a surface layer interface 214, and a coupling layer 230. In an example, the surface layer 210 is pliable. For instance, the surface layer 210 complies with the contours or profile of an underlying board 100 (as describe previously relative to Figure 1). The board overlay assembly 200 is, for example, formed from pliable components. In examples, the surface layer interface 214 and the coupling layer 230 include pliable materials that conform to the contour or profile of the board 100. For instance, the board overlay assembly 200 pliably conforms to the board 100 and thereby provides surface to surface coupling therebetween. For example, the surface layer 210 is coupled along the surfaces (e.g., the top surface 111, opposing bottom surface 113 or the two or more side surfaces 115) of the board 100. In an example, the surface layer 210 is applied to at least three sides of the board 100.

[0047] In another example, the board overlay assembly 200 is formed from a less pliable (e.g., molded or extruded-type shell) material. Optionally, the surface layer 210 is formed from High Density Polyethylene (HDPE), Low Density Polyethylene (LDPE) or polypropylene. The material selected for the board overlay assembly 200 components is specified by purpose. In some examples, the board overlay assembly 200 used in situations is not specified to flex or deform in a significant manner (e.g., in the manner of decking). In these circumstances, a pliable surface to surface coupling between the board overlay assembly 200 and the board 100 having a contoured (e.g., irregular) surface is not required, and instead the board overlay assembly 200 includes relatively rigid materials, such as HDPE. In some examples, a more pliable board overlay assembly 200 is used to achieve the desired fit of the overlay to the board 100.

[0048] The surface layer 210 is an example of an outer layer of the board overlay assembly 200. In an example, the surface layer 210 is a strip, ribbon, slab, sheet, or the like. In an example, the surface layer 210 formed from a polymer material. In some examples, the surface layer 210 includes a surface layer interface 214 an inner, or under, an inner surface and an exterior face 212 as an opposed side portion of the surface layer 210. For instance, the surface layer interface 214 facilitates coupling with the board 100 (e.g., adhering, fastening or the like) in a complementary manner to the board 100.

[0049] The surface layer 210 is, for example, pliable, or semi-pliable, and covers the board 100. For instance, when coupled to the board 100, the surface layer 210 protects the board 100 from environmental, or outdoor, elements that cause wear or degradation (e.g., moisture, particulates, changes in temperature, sunlight, use foot or hand traffic or the like). To assist with protecting the board 100, the board overlay assembly 200 includes one or more flashing drapes 220 positioned along one or more edge portions 216 of the surface layer 210. In an example, the one or more flashing drapes 220 are pliable. For instance, the one or more flashing drapes 220 pliably wrap (e.g., bend, curve, flex, conform or the like) over one or more corner portions 117 of the board 100. The one or more flashing drapes 220 extend along at least one of the two or more side surfaces 115 to decrease moisture accumulation between the surface layer 210 and the board 100. The one or more flashing drapes 220, in some examples, extend a specified distance along a side portion of the board 100 to allow for moisture to stream, roll, flow, or otherwise travel away from the surface layer 210 and the underlying board 100 and the surface layer 210. Directing the moisture in a lateral direction along the board 100 and the surface layer 210 toward the one or more flashing drapes 220 is, for example, a short distance (e.g., the least distance) for moisture to travel and direct the moisture off the surface layer 210. In examples, the surface layer 210 has a curved or angled profile, to direct moisture away from central regions of the board 100 and the overlying surface layer 210, such as the exterior face 212.

[0050] The one or more flashing drapes 220 extend from the one or more edge portions 216 of the surface layer 210. For instance, the one or more flashing drapes 220 extend at an angle away from the exterior face 212. In a coupled configuration with a board 100, the one or more flashing drapes 220 extend at, for instance, oblique angles from the one or more edge portions 216 relative to the exterior face 212 of the surface layer 210. In one example, the one or more flashing drapes 220 are formed to extend beyond the one or more corner portions 117 of the board 100. In an example, the one or more flashing drapes 220 are formed to pliably wrap over the one or more corner portions 117.

[0051] In certain examples, the one or more flashing drapes 220 incorporates various curvature profiles to accommodate different board configurations and installation requirements. In some examples, the one or more flashing drapes 220 includes a substantially curved profile that promotes water streaming off the board 100 surface. In other examples, the one or more flashing drapes 220 includes a straight angle profile when used against fascia boards or in flush mounting applications. In further examples, the one or more flashing drapes 220 is formed with an obtuse angle profile to accommodate specialized corner installations or transitional areas.

[0052] The curvature profile of the one or more flashing drapes 220 is optionally different between each of the two or more side surfaces 115 of the board overlay assembly 200 to accommodate asymmetric installation requirements. For example, at least one of the one or more flashing drapes 220 positioned along the surface layer 210 includes a first curvature profile while another of the one or more flashing drapes 220 positioned on an opposing edge includes a second curvature profile different from the first curvature profile. In examples where the board overlay assembly 200 is installed adjacent to a wall, railing, or other structure, the flashing drape proximate to the structure is configured with a modified profile to provide fit and moisture diversion. In some examples, the one or more flashing drapes 220 is provided with a specified width and complementary to the side of the board 100. The one or more flashing drapes 220, for instance, couples along the side of the board 100. The one or more flashing drapes 220, optionally, isolates the side of the board 100 and diverts moisture away from the board 100. The one or more flashing drapes 220, for instance, reduces moisture accumulation between the surface layer surface layer 210 and the board. The one or more flashing drapes 220, for instance, extends along the two or more side surfaces 115 of the board 100, and diverts moisture (e.g., directs, streams or the like) away from the board 100. Reducing moisture away from the board 100, in some examples, increases the lifespan of the board 100.

[0053] The one or more flashing drapes 220 is optionally on both of the two or more side surfaces 115 of the board 100, for instance provided along or extending from each of the opposed one or more edge portions 216 of the surface layer 210. In an example, the one or more flashing drapes 220 includes the one or more edge portions 216 of the surface layer 210. In an example with two of the one or more flashing drapes 220, the each of the one or more flashing drapes 220 are positioned on opposite sides, in a widthwise direction, of the surface layer 210.

[0054] The surface layer 210 optionally includes a coating 211, such as a polymer or an acrylic. The coating 211 in some examples is applied to at least a portion of the exterior face 212. In some examples, the coating 211 enhances one or more of durability, toughness, or the like of the surface layer 210. The coating 211 is optionally painted, sprayed, or otherwise applied on the surface layer 210. For instance, the coating 211 is applied during the manufacturing process as the surface layer 210 is formed (e.g., extruded, or coextruded) or subsequent to the surface layer production (e.g., after setting of the surface layer). In one example, the surface layer 210 is co-extruded with the coating 211 having enhanced properties. In another example, the surface layer 210 optionally includes the coating 211 that applies a streaked wood grain appearance to the board overlay assembly 200.

[0055] The coating 211 is, for instance, applied to the exterior face 212. The exterior face 212 is a surface of the surface layer 210 that faces toward the exterior (e.g., away from the board). For instance, the coating 211 includes a laminated layer that includes, but is not limited to, an image, color, pattern, or profile that is applied to the surface layer 210 and provides the image, color, pattern, or profile along the exterior face 212. Optionally, the coating 211 includes a texture surface. The exterior face 212, in some examples, extends along a width of the surface layer 210 and a length of the surface layer 210. For instance, the exterior face 212 extends along the surface layer 210 from proximate to one of the one or more flashing drapes 220 to proximate to a laterally opposing second of the one or more flashing drapes 220.

[0056] In some examples, the coating 211, includes appearance of a textured or partially textured surface, such as painting, pictures or the like that provide an aesthetic or decorative appearance as well as a profile including a texture. Optionally, the surface layer is printed with a pattern, texture, solid print, or the like during manufacturing.

[0057] Illustrated in Figure 3 is a schematic of a cross section of a board overlay assembly 300 including a surface layer 310, a surface layer interface 314, and an adhesive layer 330 (e.g., the coupling layer 230 described in reference to Figure 2) coupled to the board 100. The board 100 includes components of decks, patios, walkways, railings, fences, furnishings or the like, that are constructed from, for example, slats, planks, panels, beams, or other structural members. In an example, a textured surface 311 is extends along an exterior face 312 of the surface layer 310. In some examples, the exterior face 312 includes a textured or partially textured surface. The exterior face 312 including the textured surface 311 is, for example, imprinted, molded, or otherwise formed on the exterior face. In other examples, the textured surface is applied to the exterior face 312. The textured surface 311, in some examples, is a tractional surface such as a non-slip surface, or a surface that minimizes the likelihood of slipping on the surface layer 310.

[0058] Opposed to the exterior face 312 of the surface layer 310 is the surface layer interface 314. The surface layer interface 314, for instance, is coupled with the adhesive layer 330. The adhesive layer 330, for instance, is an intermediary layer disposed between the surface layer interface 314 of the surface layer 310 and the board 100. In an example, adhesive layer 330 an adhesive. The adhesive layer 330, for instance, joins the surface layer 310 with the board 100.

[0059] The adhesive layer 330, for instance, extends from one of the one or more corner portions 117 to an opposing of the one or more comer portions 117. The adhesive layer 330 is in contact with the surface layer interface 314, such as from one junction portion 316 of the surface layer interface 314 to an opposing junction portion 316. The junction portion 316 includes, for example, the portion of the surface layer interface 314 that includes the location where a flashing drape 320 extends from a central portion of the surface layer 310. The central portion of the surface layer 310 includes for instance the area of the surface layer 310 that corresponds to the exterior face 312. The adhesive layer 330 extends to one junction portion 316 of the surface layer interface 314 to couple the surface layer 310 to the board 100.

[0060] Illustrated in Figure 4 is a perspective view of an example of the board 100 with a board overlay assembly 400. The board overlay assembly 400 is, for example, coupled with the board 100. The board overlay assembly 400 includes a surface layer 410 as an outermost layer of the board overlay assembly 400. The surface layer 410 includes an exterior face 412. The exterior face 412 is, for instance, similar to the exterior face 212, 312 as described previously. The exterior face 412 includes an engagement surface 431 as an example of a surface which a user engages with during use of the board overlay assembly 400. The engagement surface 431 is, for example, the surface the user walks on, touches or otherwise engages with during use.

[0061] The engagement surface 431 extends, for example, along a width direction 441 and a length direction 443 of the board 100. For instance, the surface layer 410 including the engagement surface 431 extends along the board 100. For instance, the surface layer 410 is formed to cover the board 100. In examples, the engagement surface 431 extends along the surface layer 410 in areas that correspond to the top surface 111 of the board 100. For instance, the engagement surface 431 extends along the surface layer 410 from flashing drape 420 toward an opposing flashing drape 420. In another example, the engagement surface 431 extends from flashing drape 420 toward an opposing side of the surface layer 410.

[0062] The exterior face 412, is an exterior facing surface and includes, for example, a textured or partially textured surface as at least a portion of the engagement surface 431. In an example, the exterior face 412 is formed to direct moisture away from the surface layer 410 in a lateral (or widthwise) direction and towards the flashing drape 420. Directing the moisture in a lateral direction is, for example, the shortest distance for moisture to travel and directed off the surface layer 410. In examples, the surface layer 410 includes a curved profile, including a slightly curved profile, to direct moisture away from central regions, such as the engagement surface 431 of the board 100 or surface layer 410. As illustrated in Figure 4, the board overlay assembly 400 is applied to the board 100, for example, with the flashing drape 420 extending beyond the one or more corner portions 117 of the board 100. For instance, the flashing drape 420 is designed to cover the one or more comer portions 117 of the board 100 allow moisture to be flow, pass, or otherwise move away from the surface layer 410. For instance, the flashing drape 420 extend from the engagement surface 431 and along at least one of the two or more side surfaces 115 of the board 100. The flashing drape 420 extending along the two or more side surfaces 115 promotes a flow of moisture away from the engagement surface 431 and away from the board 100.

[0063] Illustrated in Figures 5A and 5B are two examples of an orientation of a flashing drape (as described previously) relative to the board 100. The flashing drape (as described previously), in some examples, is pliable, or slightly pliable, and wraps around, envelops, or extends along or partially extends around a side of a board (such as an outdoor board including outdoor flooring). The flashing drape, in some examples, is formed to extend along substantially all, or beyond a midpoint of the side of the board. In some examples it is beneficial to have the flashing drape extend beyond the midpoint of the side of the board. For example, the flashing drape extends beyond the edge of the board approximately 0.75 inches (approximately 1.90 centimeters). For example, extending beyond the midpoint provides further removal of moisture away from the exterior face and minimizes moisture from infiltrating between the surface layer and the board.

[0064] The flashing drape is formed to extend a specified distance along a side of the board according to the purpose to allow for distribution of moisture away from the board. For example, the flashing drape extends beyond the edge of the board approximately 0.125 inches (approximately 0.3175 centimeters). The flashing drape includes corners that are formed to extend around a corner of the board. In other examples, the flashing drape extends beyond the midpoint of the side of the board approximately 0.75 inches (approximately 1.90 centimeters). The distance the flashing drape extends along a side of the board is selected based on factors including the board material, environmental exposure conditions, and moisture diversion requirements.

[0065] As illustrated in Figure 5A, a flashing drape 520a extends from a central portion of a surface layer 510 and partially along the thickness of the board 100 (e.g., components of decks, patios, walkways, railings, fences, furnishings or the like, that are constructed from, for example, slats, planks, panels, beams, or other structural members), such as along at least one of the two or more side surfaces 115 of the board 100 (such as the board discussed in reference to Figure 1 or 2). In some examples, the flashing drape 520a extends along at least one of the two or more side surfaces 115 of the board 100 approximately between approximately 0.125 inches to approximately 0.5 inches (approximately 0.3 centimeters to approximately 1.27 centimeters). In this example, the flashing drape 520a promotes moisture from remaining on an exterior face 512 of surface layer 510.

[0066] In an example, the flashing drape 520a extends from the exterior face 512 of the surface layer 510 proximate to a flashing drape corner 522a. The flashing drape comer 522a is formed, for instance, to promote moisture being drawn away from the exterior face 512. In some examples, the flashing drape comer 522a extends around the one or more comer portions 117 of the board 100. For instance, the flashing drape corner 522a is formed to pliably wrap over the one or more corner portions 117.

[0067] Illustrated in Figure 5B is another example of a flashing drape 520b configuration. The flashing drape 520b includes a flashing drape corner 522b and a flashing drape lower comer 524. The flashing drape 520b, for example extends around a lower corner 119 of a bottom the board 100 (such as the opposing bottom surface 113 discussed in reference to Figure 1). In some instances, the flashing drape 520b extend beyond a midpoint of the side of the board 100. The length of the flashing drape 520b, for example, enhances diversion of moisture away from the exterior face 512 and further decreases infiltration of moisture to the board 100. In some examples, the longer the flashing drape 520b the more the flashing drape 520b isolates the board 100 from the moisture. In an example, the flashing drape 520b extends along at least one of the two or more side surfaces 115 of the board 100 from the top surface 111 of the board 100 to the bottom surface of the board (such as the opposing bottom surface 113 discussed in reference to Figure 1). For instance, the flashing drape 520b wraps around the lower corner 119 of the board along a flashing drape lower corner 524. In some examples the flashing drape 520b fastens around the board. For instance, the flashing drape 520b “snaps”, clips, clamps, snap fits, or the like around the lower corner 119 of the board 100. In some examples, the flashing drape 520b provides an extended pathway for moisture diversion by extending at least partially along the bottom surface 113 of the board 100.

[0068] Illustrated in Figure 6A, 6B and 6C are examples of different orientations of coupling layers 630a, 630b, and 630c, respectively, that reduce interference of the coupling layer with a surface layer 610 and the flashing drape 620. The coupling layers 630a, 630b, and 630c includes, for instance, an adhesive layer. Optionally, a release liner 660a, 660b, and 660c are coupled with the coupling layers 630a, 630b, and 630c, respectively. The coupling layers 630a, 630b, and 630c including the adhesive is, for example, initially coupled with the release liner 660a, 660b, and 660c. The coupling layers 630a, 630b, and 630c are coupled with the surface layer interface 614a, 614b, 614c, respectively.

[0069] In an example, the adhesive is applied to the surface layer interface 614a, 614b, 614c and the release liner 660a, 660b, and 660c is joined to the adhesive to protect the adhesive before coupling the surface layer 610 to the board 100. The coupling layer 630a, 630b, and 630c, including the adhesive is, for example an adhesive material that is formed to couple, or connect, the surface layer 610 with wood, polymer, or other materials used to form the board 100.

[0070] At least one of the coupling layers 630a, 630b, and 630c, including the adhesive, is configured, for instance, in various application patterns to optimize performance with different board materials and installation environments. In some examples, as illustrated in Figures 6A, 6B, and 6C, the adhesive (as one of the coupling layers 630a, 630b, and 630c) is applied in different configurations relative to a respective surface layer interface 614a, 614b, 614c. Beyond these configurations, additional adhesive arrangements are contemplated to address specific installation requirements.

[0071] In one example, at least one of the coupling layers 630a, 630b, and 630c includes a pressure sensitive adhesive specifically formulated for wood substrate compatibility. The pressure sensitive adhesive is configured to form a strong bond with natural lumber while accommodating the natural expansion and contraction characteristics of wooden boards. In another example, at least one of the coupling layers 630a, 630b, and 630c includes a different pressure sensitive adhesive formulated for adhesion to composite or polymer-based boards. The specific adhesive chemistry is selected based on the underlying board material to ensure long-term performance. The thickness of at least one of the coupling layers 630a, 630b, and 630c (including the adhesive) is optionally varied across a corresponding surface layer interface 614a, 614b, 614c. In some examples, the adhesive is applied with greater thickness in high-stress areas such as relative to the central portion of the board 100 where foot traffic is concentrated. In other examples, the adhesive is applied with reduced thickness along the flashing drape 620 to maintain flexibility while ensuring sufficient coupling strength.

[0072] In applications where the board overlay assembly 200 is intended for temporary or seasonal installation, the adhesive is optionally formulated to maintain sufficient coupling strength while allowing for controlled removal without damage to the underlying board (such as board 100). Conversely, in permanent installation applications, the adhesive is formulated for maximum long-term durability and resistance to environmental factors including temperature fluctuations, moisture exposure, and UV radiation.

[0073] In some examples, the adhesive is applied in a multi-zone configuration that is beneficial for both installation efficiency and performance. For instance, the adhesive is applied to a flat (e.g., planar, even or the like) central portion of at least one of the surface layer interfaces 614a, 614b, 614c corresponding to the top surface of the board. Optionally, a gap or adhesive-free zone is provided corresponding to the corner regions, followed by additional adhesive zones corresponding to portions of the flashing drape 620 that contact the sides of the board 100. This multi-zone configuration requires removal of the release liner in multiple discrete sections during installation but provides enhanced coupling at moisture diversion regions.

[0074] The release liner 660a, 660b, and 660c includes, for example, a removable cover that is applied to the adhesive. The release liner 660a, 660b, and 660c, for example is statically coupled to the coupling layers 630a, 630b, and 630c, respectively, including the adhesive. One or more side portion release liners 660a, 660b can be coupled to the side portions of coupling layer 665a, 665b associated with a side portion of a board or the surface layer 610. Optionally, the release liner 660a, 660b, and 660c is formed from a plastic or a paper-like material. For example, the release liner 660a, 660b, and 660c is applied to an outwardly facing surface 637a, 637b, 637c of the adhesive. As illustrated in Figure 6A, the coupling layer 635a extends along substantially all of the surface layer interface 614a including the surface layer interface 614a corresponding to the flashing drape 620. The coupling layer 635a including an adhesive extends, for example, along the entire, or substantially the entire, the surface layer interface 614a. For instance, the coupling layer 635a including the adhesive has an inwardly facing surface 633a as the portion of the adhesive in contact, such as direct contact, with the surface layer interface 614a and an outwardly facing surface 637a as the portion of the coupling layer 635a including the adhesive that is exteriorly facing, such as facing the board. In examples, the coupling layer 635a including the adhesive conforms with the surface layer interface 614a as the surface layer 610 is pliably formed to the board. For instance, the coupling layer 635a including the adhesive of the is minimally, if at all, detached from or not applied to the surface layer interface 614a if the surface layer 610 bends, flexes, or otherwise deforms. For example, the adhesive is applied or extends continuously, substantially continuously, or at specified locations along a central portion of the surface layer interface 614a.

[0075] In examples, the release liner 660a is coupled with the outwardly facing surface 637a of the coupling layer 630a. For instance, the release liner 660a is located or positioned along the outwardly facing surface 637a of the adhesive (as an example of the coupling layer 630a) to protect the adhesive. The release liner 660a, in other instances, is located or positioned along the outwardly facing surface 637a to reduce a likelihood of the coupling layers 630a including the adhesive from attaching or being coupled with undesired surfaces.

[0076] As illustrated in Figure 6B, the coupling layer 630b including the adhesive is selectively applied to the surface layer interface 614b. For example, a side coupling layer 635b, as the adhesive, is applied to a portion of the surface layer interface 614b that is between one or more flashing drape comer 622 of the surface layer 610. In other examples, the adhesive is applied proximate to the one or more flashing drape corner 622, but not on the surface layer interface 614b corresponding to the one or more flashing drape comer 622, such as the side coupling layer 635b. The adhesive is optionally applied to selective portions of the surface layer interface 614b corresponding to the flashing drape 620. For instance, the adhesive is applied to portions of the surface layer interface 614b corresponding to the flashing drape 620 in areas removed from the one or more flashing drape corner 622.

[0077] In the example illustrated in Figure 6B, a release liner 660b is positioned or located along the outwardly facing surface 637b of the adhesive (as the coupling layer 630b) to protect the adhesive. The release liner 660a, in other instances, is located or positioned along the outwardly facing surface 637b to reduce a likelihood of the coupling layers 630b including the adhesive from attaching or being coupled with undesired surfaces. For instance, there is a break (e.g., gap, space, opening or the like) between portions of the release liner 660b corresponding to a portion of the coupling layer 630b associated with the flashing drape 620 and a portion of the coupling layers 630b associated with an exterior face 612 of the surface layer 610.

[0078] Including the break (e.g., gap, space, opening or the like) along the coupling layer 630b permits the surface layer 610 to be pliably wrapped around an underlying board (such as the board described previously) without the coupling layer 630b being coupled with underlying board along the comers. The release liner 660b is coupled along the portions of the coupling layer 630b and avoiding the portions of the surface layer 610 corresponding to the one or more flashing drape comer 622.

[0079] Illustrated in Figure 6C is an example of another orientation or application of the coupling layer 630c coupled along a selected portion of the surface layer interface 614c. For example, the coupling layers 630c including the adhesive is coupled or applied to an inwardly facing surface 633c such as a central portion of the surface layer interface 614c. In an example, the coupling layer 630c including the adhesive is coupled with the surface layer interface 614c of the surface layer 610 along one or more locations or positions between at least the one or more flashing drape comer 622.

[0080] Optionally, a release liner 660c is coupled with an outwardly facing surface 637c of the coupling layer 630c. For instance, the release liner 660c extends along an outwardly facing surface 637c of the coupling layer 630c between the one or more flashing drape corner 622.

[0081] Illustrated in Figure 7 is an example of a multi-component coupling layer 730 including one or more flashing drapes 720. The multi-component coupling layer 730 includes components that are mechanical coupled, or fixed, together. In some examples, the one or more flashing drapes 720 are located on opposing lateral sides of the multi-component coupling layer 730. In some examples, the board overlay assembly 700 includes the multi-component coupling layer 730 having one or more fasteners 775 or adhesives to join a surface layer 710 with the board 100. The multi-component coupling layer 730 includes, for example, a first mating layer 772 and a second mating layer 774. For example, the first mating layer 772 is coupled with, for example, the surface layer interface 714. The first mating layer

[0082] 772 is optionally coupled with the surface layer interface 714 with a fastener such as a nail, screw, bolt, staple, or the like. Optionally, the first mating surface interface

[0083] 773 is coupled with the surface layer interface 714 with an adhesive layer 771. Optionally, the adhesive layer 771 is positioned between the surface layer interface 714 and a first mating surface interface 773.

[0084] The second mating layer 774 is optionally coupled with the board 100. The second mating layer 774, in some examples, is coupled with the board 100 with a fastener such as a nail, screw, bolt, staple or the like. In other examples, the second mating layer 774 is coupled with the board 100 with an adhesive layer 779.

[0085] The first mating layer 772 and the second mating layer 774 are, for example, coupled, such as fixedly attached to each other. For example, the first mating layer 772 and the second mating layer 774 are mechanically coupled, or fixed, together with a snap fit, hook and loop, interference fit, intermediate adhesive or the like. In some examples, fixedly attached includes additional mechanical forces are required to decouple the first mating layer first mating layer 772 and the second mating layer 774.

[0086] In some examples the first mating layer 772 and the second mating layer

[0087] 774 are provided laterally across the board 100 and the surface layer interface 714. In other examples, the first mating layer 772 and the second mating layer 774 are provided longitudinally along the length of the board 100 at specified locations of the surface layer interface 714.

[0088] Illustrated in Figure 8 is an example of a board overlay assembly 800 including a multi-component surface layer assembly 805. The multi-component surface layer assembly 805 includes a first board overlay assembly 801 and a second board overlay assembly 802. The first board overlay assembly 801 and the second board overlay assembly 802 are, for example, similar to the board overlay assemblies discussed previously. For instance, surface layer 810 includes one or more flashing drapes 820. While the one or more flashing drapes 820 are illustrated to appear similar, each of the one or more flashing drapes 820 optionally includes different dimensions or profiles.

[0089] The multi-component surface layer assembly 805 includes, for example, a mating region 880. The mating region 880, for example, is positioned at a first longitudinal end portion 882 of the first board overlay assembly 801 and at a second longitudinal end portion 884 of the second board overlay assembly 802. The mating region 880 includes, for example a first mating portion 881 including a stepdown portion 883, relative to the height of the one or more flashing drapes 820, that is less than a more central portion of the surface layer 810.

[0090] The second board overlay assembly 802 includes a second mating portion 885 that, for example, includes a receiving portion that fits over or under the stepdown portion 883. For instance, the second mating portion 885 covers (e.g., caps, wraps, encases, or the like) the first mating portion 881. In an example, the first mating portion 881 and the second mating portion 885 are coupled with one or more of a snap-fit connection, clearance fit (e.g., sliding fit), or an interference fit connection that is located on top of, around, or the like.

[0091] In an example, the first mating portion 881 including the step-down portion 883 is coupled with the board (such as board 100 discussed previously) with one or more fastening mechanisms. For example, a fastening mechanism can include the first mating portion 881 be coupled with the board with a snap fit, interference fit, clearance fit or the like. In another example, fastening feature 887 can include a fastener such as staples, screws, bolts, nails or the like. In another example, the fastening feature 887 can include an adhesive. In yet another example, more than one fastening features 887 can be used to couple the first board overlay assembly 801 with the board.

[0092] The second longitudinal end portion 884, including the second mating portion 885, in examples, fits over the first longitudinal end portion 882 including at least a portion of the first mating portion 881. The second mating portion 885 is optionally coupled with the first mating portion 881 with one or more of a snap fit, clearance fit, interference fit or the like. Optionally, the first mating portion 881 and the second mating portion 885 are coupled together with an adhesive, fastener or the like. In some examples, the mating region 880 region accommodates for thermal expansion or contraction of the board overlay assembly 802 relative to the first board overlay assembly 801, or the first board overlay assembly 801 relative to the second board overlay assembly 802. In another example, the first mating portion 881 and the second mating portion 885 are coupled to allow for the board (such as board 100) to expand or contract.

[0093] Illustrated in Figure 9 is an example of a board overlay assembly 900 as a component of an outdoor flooring overlay assembly, or the like. The board overlay assembly 900 includes, for instance, a first board 100a and a second board 100b. In an example, the first board 100a and the second board 100b are similar to board 100 (e.g., components of decks, patios, walkways, railings, fences, furnishings or the like, that are constructed from, for example slats, planks, panels, beams, or other structural members) discussed previously.

[0094] The first board 100a includes, for example, a first board overlay assembly

[0095] 901. The second board 100b optionally includes a second board overlay assembly

[0096] 902. The first board overlay assembly 901 and the second board overlay assembly 902 include an exterior face 912a, 912b, respectively and a surface layer interface 914a, 914b, respectively. The first board overlay assembly 901 and the second board overlay assembly 902 are coupled to the first board 100a and the second board 100b as discussed previously.

[0097] In an example, each of the first board overlay assembly 901 and the second board overlay assembly 902 include one or more flashing drapes 920. The one or more flashing drapes 920 are similar to the flashing drapes discussed previously. The one or more flashing drapes 920 incorporates varying thickness profiles along its length to optimize performance. In some examples, the one or more flashing drapes 920 is thicker at the junction with the exterior face 912a, 912b and progressively thins toward its terminal edge. This tapering promotes capillary action that draws moisture away from at least one of the first board 100a or the second board 100b while minimizing material usage and enhancing flexibility during installation.

[0098] When installed on adjacent boards, the one or more flashing drapes 920 from neighboring first board overlay assembly 901 and second board overlay assembly 902 cooperate to form a controlled drainage system. Water migrating off each of the exterior faces 912a, 912b is optionally directed down the one or more flashing drapes 920 into a gap between adjacent boards (e.g., first board overlay assembly 901 and second board overlay assembly 902). The geometry of the one or more flashing drapes 920 directs the moisture downward and away from, for example, the deck structure. This drainage system optionally maintains a drainage pattern of the original flooring design while adding an additional protective layer that prevents direct contact between moisture and the board 100.

[0099] Optionally, the one or more flashing drapes 920 have a tapered profile that are thicker closer to the exterior face 912a, 912b than a bottom surface of the board 100. Optionally, the one or more flashing drapes 920 is thinner (narrower, drawn, stretched) proximate to the end portions of each of the one or more flashing drapes 920 than a portion closer to the exterior face 912a, 912b. For example, each of the one or more flashing drapes 920 promotes moisture flowing away from the exterior face 912a, 912b and away from the first board 100a or the second board 100b, respectively. In an example, each of the one or more flashing drapes 920 thins to promote moisture flowing away from the exterior faces 912a, 912b and down or along the one or more flashing drapes 920. Optionally, one or more of the flashing drapes 920 thins to allow for better fitting of adjacent flashing drapes on one side or edge portion of a board adjacent to the flashing drape of the other adjacent board.

[0100] In examples, the tapered configuration of the one or more flashing drapes 920 allows the first board 100a and the second board 100b to be positioned closer to each other than in arrangements with the one or more flashing drapes 920 having a substantially consistent thickness along the length. Optionally, the board overlay assembly 900 includes several boards (such as first board 100a and second board 100b) including exterior face 912a and exterior face 912b arranged, located, or positioned adjacent to the other.

[0101] Illustrated in Figure 10 is a schematic view of the board overlay 1000 supplied in a relatively flat configuration (e.g., relatively planar, unrolled, unfolded, straightened, or the like). The relatively flat configuration is an example of a form of the board overlay 1000 before installation. In the example illustrated in Figure 10, the board overlay 1000 includes at least one portion that corresponds to the corner of a board onto which the board overlay 1000 is applied.

[0102] The board overlay 1000 includes, for example, an exterior face 1012 of a surface layer 1010 as the outwardly facing surface when the board overlay 1000 is applied to the board (such as board 100 described previously). The board overlay 1000 includes, in some examples, a coupling layer 1030 including an adhesive. The coupling layer 1030 including an adhesive, for instance, is coupled with a surface layer interface 1014. In examples, the coupling layer 1030 is pushed, forced, or inserted into grooves in the surface layer interface 1014 that correspond to one or more flashing drape corner portions 1022. The board overlay 1000 optionally includes a release liner 1060 coupled with the coupling layer 1030 along a surface opposed to the surface layer interface 1014.

[0103] The surface layer 1010 including the exterior face 1012, in an example, is located between opposing flashing drapes 1020. For example, the exterior face 1012 is located along a central portion of the board overlay 1000 when in a substantially flat configuration. The flashing drapes 1020 are located proximate to edge portions of the board overlay 1000.

[0104] Positioned between the flashing drapes 1020 portion of the board overlay 1000 and the exterior face 1012 of the surface layer 1010 are one or more flashing drape comer portions 1022. The one or more flashing drape comer portions 1022 is, for example, formed to be folded, wrapped, or otherwise applied to a corner portion of the board. The one or more flashing drape corner portions 1022 is formed to transition the board overlay 1000 from a substantially planar sheet to a form that corresponds to the board. The one or more flashing drape comer portions 1022 includes, for instance, grooves (e.g., waves, undulations, contours, or the like) in the surface layer interface 1014 that promotes ease in conforming the board overlay 1000 to the shape (e.g., radius or angle) of a board comer. While three grooves are illustrated, fewer grooves or more grooves are optionally used.

[0105] In an example, when folded (e.g., bent or the like) the one or more flashing drape comer portions 1022 and the flashing drapes 1020, forms the flashing drape portions that corresponds to the side portions of the board. In the flat configuration, a folding area 1023 is formed that includes one or more grooves, recesses, cavities or the like to accommodate for the bend or corner when the board overlay 1000 is applied to the board. The flashing drape portion, in an applied configuration, formed when the folding area 1023 is applied to a corner of a board directs moisture or water away from the board and the exterior surface.

[0106] Illustrated in Figure 11 is a schematic of a method of manufacturing a board overlay 1100, as described previously. The method includes, for example, extruding a material 1102, such as a polymer, through an extruder 1101. The material 1102 flowing from the extruder 1101 passes, for example, into chilled profile rollers 1103. The chilled profile rollers 1103 optionally form the surface layer material

[0107] 1104, such as the surface layers described previously.

[0108] The chilled profile rollers 1103, for example, stamp, stretch, or form a contour profile on the surface layer material 1104. While stated as a chilled profile roller, the rollers include optionally a heated roller that deforms the material 1102. In examples with the heated roller, the material 1102 is set or cooled. Optionally, the material 1102 that passes through heated rollers pass through the chilled profile rollers 1103. The chilled profile rollers 1103 form, for example, an exterior face of the surface layer material 1104 and optionally form a texture or pattern on the exterior face.

[0109] The method of forming the board overlay 1100 includes deforming at least one or more edge portions of the surface layer. Optionally, the at least one or more edge portions are deformed with one of the chilled profile rollers 1103 or the heat roller. The deforming, for example, forms corners based on the deforming of the one or more edge portions. In an example, the deforming transitions the one or more edge portions to the one or more flashing drapes. Optionally, the chilled profile rollers 1103 form one or more undulations or grooves in areas of the surface layer interface corresponding to the one or more edge portions to facilitate bending or folding at installation.

[0110] The method optionally includes applying adhesive to a second side 1106 of the surface layer material 1104. For instance, a release liner 1108 from a release liner roll 1107 passes through an adhesive application device 1105, such as a glue head. In an example, at least one side of the release liner 1108 has the adhesive applied. In some examples, the at least one side is coated with the adhesive. In other examples, adhesive is spot applied or applied at only specified locations.

[0111] One or more pull rollers 1109, 1111, for example, pulls or draws the surface layer material 1104, as the surface layer, additional intermediary such as the adhesive and a release liner to bind, join, couple or the like together. Optionally, additional layers such as cushioning, environmental control layers or the like are coupled with the surface layer and the adhesive. In some examples, the surface layer material 1104 is pulled or drawn through the pull rollers 1111 after the surface layer material 1104 has passed through chill rollers thereby forming an overlay assembly 1110.

[0112] In some examples, multiple overlay assemblies 1110 are formed at one time (e.g., sequentially, simultaneously or at relatively similar times). The multiple overlay assemblies 1110 are, for instance, separated into individual overlay assemblies 1110 with the trim slitter 1113. In other examples, the trim slitter 1113, or other similar devices, trims or cuts outside edge portions of the overlay assembly 1110. In some examples, the overlay assembly 1110 is cut into the desired lengths. The overlay assembly 1110, in some examples, is supplied as lengths or strips of the overlay. In other examples, the overlay assembly 1110 are supplied as rolls of overlay.

[0113] Various Notes and Aspects

[0114] Aspect 1 can include subject matter such as a board overlay including: a surface layer having a first edge portion and a second edge portion, the first edge portion and the second edge portion extending along a length of the surface layer, the surface layer including: an exterior face positioned between the first edge portion and the second edge portion; one or more pliable flashing drapes positioned on at least one of the first edge portion and the second edge portion; wherein the one or more flashing drapes are configured to pliably wrap over one or more of the first edge portion or the second edge portion; and a surface layer interface opposed to the exterior face; and a coupling layer coupled with the surface layer interface.

[0115] Aspect 2 can include, or can optionally be combined with the subject matter of Aspect 1, to optionally include a first flashing drape positioned on the first edge portion and a second flashing drape positioned on the second edge portion.

[0116] Aspect 3 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 or 2 to optionally include the exterior face includes one or more of a textured surface or a laminated surface.

[0117] Aspect 4 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-3 to optionally include the coupling layer includes an adhesive and a removable liner.

[0118] Aspect 5 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-4 to optionally include the adhesive is configured to join the surface layer with a board; wherein the one or more flashing drapes are configured to pliably wrap around a corresponding comer of the board.

[0119] Aspect 6 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-5 to optionally include the surface layer includes a polymer. Aspect 7 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-6 to optionally include the one or more flashing drapes includes an engagement protrusion positioned proximate to a free end of the one or more flashing drapes.

[0120] Aspect 8 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-7 to optionally include the coupling layer includes a first mating layer configured to be coupled with the surface layer interface and a second mating layer configured to be coupled with an outdoor board; wherein the first mating layer and the second mating layer are configured to be reciprocally coupled.

[0121] Aspect 9 can include subject matter such as a board overlay assembly comprising: a surface layer including: an exterior textured face extending along the surface layer; and a first flashing drape and a second flashing drape coupled along a length of the surface layer; wherein the first flashing drape and the second flashing drape each wrap over one or more edge of an outdoor flooring board; a surface layer interface opposed to the exterior textured face; and an adhesive coupled with the surface layer interface.

[0122] Aspect 10 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9 to optionally include an outdoor flooring panel; wherein the outdoor flooring panel is coupled with the board overlay assembly; and wherein at least one of the first flashing drape and the second flashing drape narrows along the length of the first flashing drape or the second flashing drape.

[0123] Aspect 11 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-10 to optionally include the first flashing drape is configured to extend around a first side portion of the outdoor flooring panel; the second flashing drape is configured to extend around a second side portion of the outdoor flooring panel.

[0124] Aspect 12 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-11 to optionally include the exterior textured face includes a texture extending continuously along the length of the surface layer.

[0125] Aspect 13 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-12 to optionally include a first board overlay assembly including a first flashing drape and a second flashing drape, the first board overlay is configured to be positioned on an outdoor flooring panel; and a second board overlay including a third flashing drape and a fourth flashing drape, the second board overlay is configured to be positioned on an adjacent outdoor flooring panel; wherein the second flashing drape of the first board overlay assembly faces a third flashing drape of the second board overlay assembly.

[0126] Aspect 14 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-13 to optionally include the adhesive is configured to couple the surface layer with a surface of an elongate outdoor flooring.

[0127] Aspect 15 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-14 to optionally include the adhesive is deposited along a central portion of the surface layer coupling interface.

[0128] Aspect 16 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-15 to optionally include the surface layer is formed from one or more of a polymer or high density polyethylene.

[0129] Aspect 17 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 9-16 to optionally include a release liner positioned in covering relationship with the adhesive.

[0130] Aspect 18 can include subject matter such as a method of forming an outdoor flooring overlay including: extruding a polymer sheet into a surface layer, the surface layer having an exterior face area and a surface layer interface; forming one or more flashing drapes along the surface layer, including: deforming at least one or more edge portions of the surface layer into the one or more flashing drapes; wherein the one or more flashing drapes maintains pliability; and applying a coupling to the surface layer interface.

[0131] Aspect 19 can include, or can optionally be combined with the subject matter of Aspect 18, to optionally include forming a comer along the surface layer based on the deforming of the at least one or more edge portions; and transitioning the one or more edge portions to the one or more flashing drapes including the corner based on the deforming the at least one or more edge portions.

[0132] Aspect 20 can include, or can optionally be combined with the subject matter of Aspect 18-19, to optionally include forming one or more undulations in an area of the surface layer interface corresponding to the one or more edge portions.

[0133] Aspect 21 can include, or can optionally be combined with the subject matter of Aspect 18-20, to optionally include stretching the surface layer in areas corresponding to the one or more edge portions; and imparting a curvature to the surface layer corresponding to the one or more edge portions.

[0134] Aspect 22 can include, or can optionally be combined with the subject matter of Aspect 18-21, to optionally include passing the polymer sheet through rollers to form a texture on an exterior face of the surface layer.

[0135] Aspect 23 can include, or can optionally be combined with the subject matter of Aspect 18-22, to optionally include the coupling includes an adhesive, the method including: applying a release liner to the adhesive; wherein the adhesive is configured to bond with at least one or wood or polymer.

[0136] Aspect 24 can include, or can optionally be combined with the subject matter of Aspect 18-23, to optionally include forming a texture on the surface layer; wherein forming one or more flashing drapes includes forming a comer having a radius on a first edge portion and a second edge portion; wherein the texture formed is between the first edge portion and the second edge portion.

[0137] Aspect 25 can include subject matter such as an outdoor flooring overlay assembly comprising a first surface layer having a first longitudinal end portion including: one or more first flashing drapes positioned on at least one side of the first surface layer; and a first mating region positioned proximate to at the first longitudinal end portion; a second surface layer having a second longitudinal end portion including: one or more second flashing drapes positioned on at least one side of the second surface layer; and a second mating region positioned proximate to the second longitudinal end portion; wherein the first mating region and the second mating region are configured to be coupled; and a coupling layer configured to join each of the first surface layer and the second surface layer with a board.

[0138] Aspect 26 can include, or can optionally be combined with the subject matter of Aspect 25, to optionally include the first mating layer configured to be in interference fit engagement with the second layer; wherein the first mating layer and the second mating layer are configured to accommodate for thermal expansion of the board.

[0139] Aspect 27 can include, or can optionally be combined with the subject matter of Aspect 25-26, to optionally include wherein the first mating layer is coupled with a board. Aspect 28 can include, or can optionally be combined with the subject matter of Aspect 25-27, to optionally include wherein the first mating layer is coupled with the board with an adhesive layer.

[0140] Aspect 29 can include, or can optionally be combined with the subject matter of Aspect 25-27, to optionally include the surface layer includes a texture, and the surface layer promotes lateral water diversion.

[0141] Aspect 30 can include subject matter such an outdoor flooring overlay assembly comprising a first surface layer having a first longitudinal end portion including: one or more first flashing drapes positioned on at least one side of the first surface layer; and a first mating region positioned proximate to at the first longitudinal end portion; a second surface layer having a second longitudinal end portion including: one or more second flashing drapes positioned on at least one side of the second surface layer; and a second mating region positioned proximate to the second longitudinal end portion; the first mating region and the second mating region are configured to be coupled; and a coupling layer configured to join each of the first surface layer and the second surface layer with a board.

[0142] Aspect 31 can include, or can optionally be combined with the subject matter of Aspect 30, to optionally include the first mating region and the second mating region are coupled configured to be in clearance fit engagement.

[0143] Aspect 32 can include, or can optionally be combined with the subject matter of Aspect 30-31, to optionally include at least one of the first mating region and the second mating region are coupled to a board with at least one of one or more fasteners or an adhesive.

[0144] Aspect 33 can include, or can optionally be combined with the subject matter of Aspect 30-32, to optionally include the first mating region and the second mating region are configured to accommodate thermal expansion of a board.

[0145] Each of these non-limiting aspects can stand on its own or can be combined in various permutations or combinations with one or more of the other aspects.

[0146] The above description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as “aspects” or “examples.” Such aspects or example can include elements in addition to those shown or described. However, the present inventors also contemplate aspects or examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate aspects or examples using any combination or permutation of those elements shown or described (or one or more features thereof), either with respect to a particular aspects or examples (or one or more features thereof), or with respect to other Aspects (or one or more features thereof) shown or described herein.

[0147] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

[0148] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

[0149] Geometric terms, such as “parallel,” “perpendicular,” “round,” or “square,” are not intended to require absolute mathematical precision, unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functions. For example, if an element is described as “round” or “generally round,” a component that is not precisely circular (e.g., one that is slightly oblong or is a many-sided polygon) is still encompassed by this description.

[0150] Method aspects or examples described herein can be machine or computer- implemented at least in part. Some aspects or examples can include a computer- readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above aspects or examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an aspect or example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Aspects or examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.

[0151] The above description is intended to be illustrative, and not restrictive. For example, the above-described aspects or examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as aspects, examples, or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

THE CLAIMED INVENTION IS:

1. A board overlay including: a surface layer having a first edge portion and a second edge portion, the first edge portion and the second edge portion extending along a length of the surface layer, the surface layer including: an exterior face positioned between the first edge portion and the second edge portion; one or more flashing drapes positioned on at least one of the first edge portion and the second edge portion; wherein the one or more flashing drapes are configured to pliably wrap over one or more of the first edge portion or the second edge portion; and a surface layer interface opposed to the exterior face; and a coupling layer coupled with the surface layer interface.

2. The board overlay of claim 1, including a first pliable flashing drape positioned on the first edge portion and a second pliable flashing drape positioned on the second edge portion.

3. The board overlay of claim 2, wherein the exterior face includes one or more of a textured surface or a laminated surface.

4. The board overlay of claim 1, wherein the coupling layer includes an adhesive and a removable liner.

5. The board overlay of claim 4, wherein the adhesive is configured to join the surface layer with a board; wherein the one or more flashing drapes are configured to pliably wrap around a corresponding corner of the board.

6. The board overlay of claim 1, wherein the surface layer includes a polymer.

7. The board overlay of claim 1, wherein the one or more flashing drapes includes an engagement protrusion positioned proximate to a free end of the one or more flashing drapes.

8. The board overlay of claim 1, wherein the coupling layer includes a first mating layer configured to be coupled with the surface layer interface and a second mating layer configured to be coupled with an outdoor board; wherein the first mating layer and the second mating layer are configured to be reciprocally coupled.

9. A board overlay assembly comprising: a surface layer including: an exterior textured face extending along the surface layer; and a first flashing drape and a second flashing drape coupled along a length of the surface layer; wherein the first flashing drape and the second flashing drape each wrap over one or more edge of an outdoor flooring board; a surface layer interface opposed to the exterior textured face; and an adhesive coupled with the surface layer interface.

10. The board overlay assembly of claim 9, including an outdoor flooring panel; wherein the outdoor flooring panel is coupled with the board overlay assembly; wherein at least one of the first flashing drape and the second flashing drape narrows along the length of the first flashing drape or the second flashing drape.

11. The board overlay assembly of claim 10, wherein the first flashing drape is configured to extend around a first side portion of the outdoor flooring panel; the second flashing drape is configured to extend around a second side portion of the outdoor flooring panel.

12. The board overlay assembly of claim 9, wherein the exterior textured face includes a texture extending continuously along the length of the surface layer.

13. The board overlay assembly of claim 9, including: a first board overlay assembly including a first flashing drape and a second flashing drape, the first board overlay assembly is configured to be positioned on an outdoor flooring panel; and a second board overlay assembly including a third flashing drape and a fourth flashing drape, the second board overlay assembly is configured to be positioned on an adjacent outdoor flooring panel; wherein the second flashing drape of the first board overlay assembly faces the third flashing drape of the second board overlay assembly.

14. The board overlay assembly of claim 9, wherein the adhesive is configured to couple the surface layer with a surface of an elongate outdoor flooring.

15. The board overlay assembly of claim 9, wherein the adhesive is deposited along a central portion of the surface layer interface.

16. The board overlay assembly of claim 9, wherein the surface layer is formed from one or more of a polymer or high density polyethylene.

17. The board overlay assembly of claim 9, including: a release liner positioned in covering relationship with the adhesive.

18. A method of forming an outdoor flooring overlay including: extruding a polymer sheet into a surface layer, the surface layer having an exterior face area and a surface layer interface; forming one or more flashing drapes along the surface layer, including: deforming at least one of one or more edge portions of the surface layer into the one or more flashing drapes;wherein the one or more flashing drapes maintains pliability; and applying a coupling to the surface layer interface.

19. The method of forming the outdoor flooring overlay of claim 18 including: forming a comer along the surface layer based on the deforming of the at least one or more edge portions; and transitioning the one or more edge portions to the one or more flashing drapes including the corner based on the deforming the at least one or more edge portions.

20. The method of forming the outdoor flooring overlay of claim 18 including: forming one or more undulations in an area of the surface layer interface corresponding to the one or more edge portions.

21. The method of forming the outdoor flooring overlay of claim 18 including: stretching the surface layer in areas corresponding to the one or more edge portions; and imparting a curvature to the surface layer corresponding to the one or more edge portions.

22. The method of forming the outdoor flooring overlay of claim 18, including: passing the polymer sheet through rollers to form a texture on an exterior face of the surface layer.

23. The method of forming the outdoor flooring overlay of claim 18, wherein the coupling includes an adhesive, the method including: applying a release liner to the adhesive; wherein the adhesive is configured to bond with at least one or wood or polymer.

24. The method of forming the outdoor flooring overlay of claim 18, including: forming a texture on the surface layer;wherein forming one or more flashing drapes includes forming a comer having a radius on a first edge portion and a second edge portion; wherein the texture formed is between the first edge portion and the second edge portion.

25. An outdoor flooring overlay assembly comprising: a surface layer including: an exterior face including a surface configured to direct moisture off of the surface layer; a surface layer interface on an opposed side of the exterior face; and a first flashing drape and a second flashing drape formed on opposing lateral sides of the surface layer; wherein one of the first flashing drape and the second flashing drape are configured to direct moisture away from the exterior face; and a coupling layer including a first mating layer configured to be coupled with the surface layer interface and a second mating layer configured to be coupled with a board; wherein the first mating layer and the second mating layer are configured to be coupled.

26. The outdoor flooring overlay assembly of claim 25, wherein the first mating layer configured to be in interference fit engagement with the second layer; wherein the first mating layer and the second mating layer are configured to accommodate for thermal expansion of the board.

27. The outdoor flooring overlay assembly of claim 25, wherein the first mating layer is coupled with a board.

28. The outdoor flooring overlay assembly of claim 25, wherein the first mating layer is coupled with the board with an adhesive layer.

29. The outdoor flooring overlay assembly of claim 25, wherein the surface layer includes a texture, and the surface layer promotes lateral water diversion.

30. An outdoor flooring overlay assembly comprising: a first surface layer having a first longitudinal end portion including: one or more first flashing drapes positioned on at least one side of the first surface layer; and a first mating region positioned proximate to at the first longitudinal end portion; a second surface layer having a second longitudinal end portion including: one or more second flashing drapes positioned on at least one side of the second surface layer; and a second mating region positioned proximate to the second longitudinal end portion; wherein the first mating region and the second mating region are configured to be coupled; and a coupling layer configured to join each of the first surface layer and the second surface layer with a board.

31. The outdoor flooring overlay assembly of claim 30, wherein the first mating region and the second mating region are coupled configured to be in clearance fit engagement.

32. The outdoor flooring overlay assembly of claim 30, wherein at least one of the first mating region and the second mating region are coupled to a board with at least one of one or more fasteners or an adhesive.

33. The outdoor flooring overlay assembly of claim 30, wherein the first mating region and the second mating region are configured to accommodate thermal expansion of a board.

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